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<p>This study investigates the impact of Ni interlayers of different thicknesses and ultrasonic vibration (UV) on the macro- and microstructures of dissimilar Al/Mg friction stir butt welds, aiming to control the formation of intermetallic compounds (IMCs) and joint properties. This research investigates how the physical and chemical limitations of the Ni interlayer interact with the UV-induced acoustic softening during friction stir welding (FSW), and their combined effects have not been previously studied. The findings revealed that introducing a Ni layer can reduce the thickness of Al-Mg IMCs. The Ni interlayer, with thicknesses of 0.05 and 0.1&#xa0;mm, is effectively coupled with the ultrasonic vibrations. Improved material distribution at the interface significantly inhibited Al-Mg IMCs formation. The thickness of IMCs (Al<sub>3</sub>Mg<sub>2</sub>) has decreased from about 4&#xa0;μm to less than 2.5&#xa0;μm. Thus, the joint strength has increased by a maximum of 25.2%. Upon using the Ni interlayer thickness of 0.2&#xa0;mm, the combined application of ultrasonic vibration and the interlayer does not improve material flow within the weld nugget zone (WNZ), resulting in a weaker joint. The tensile strength of the FSW and UVeFSW joints decreased by 11.3 and 49.1%. The combined effect of ultrasonic vibration and a thicker interlayer of 0.2&#xa0;mm reduces the influence of additional energy on the joint’s overall performance.</p>

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The Role of Ni Interlayer in the Microstructural Properties of Dissimilar Ultrasonic-Assisted Al/Mg Alloy Friction Stir Welds

  • 期刊论文

  • 发表日期：

    2025年9月16日

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  • Junjie Zhao,
  • Fuhui Yang,
  • Najib Ahmad Muhammad,
  • Chuansong Wu

摘要

This study investigates the impact of Ni interlayers of different thicknesses and ultrasonic vibration (UV) on the macro- and microstructures of dissimilar Al/Mg friction stir butt welds, aiming to control the formation of intermetallic compounds (IMCs) and joint properties. This research investigates how the physical and chemical limitations of the Ni interlayer interact with the UV-induced acoustic softening during friction stir welding (FSW), and their combined effects have not been previously studied. The findings revealed that introducing a Ni layer can reduce the thickness of Al-Mg IMCs. The Ni interlayer, with thicknesses of 0.05 and 0.1 mm, is effectively coupled with the ultrasonic vibrations. Improved material distribution at the interface significantly inhibited Al-Mg IMCs formation. The thickness of IMCs (Al3Mg2) has decreased from about 4 μm to less than 2.5 μm. Thus, the joint strength has increased by a maximum of 25.2%. Upon using the Ni interlayer thickness of 0.2 mm, the combined application of ultrasonic vibration and the interlayer does not improve material flow within the weld nugget zone (WNZ), resulting in a weaker joint. The tensile strength of the FSW and UVeFSW joints decreased by 11.3 and 49.1%. The combined effect of ultrasonic vibration and a thicker interlayer of 0.2 mm reduces the influence of additional energy on the joint’s overall performance.